Mike 4001 design of the stator of electrical motor &amp; generator

ABSTRACT

When we use a new structure of stator of a motor (or generator) to let magnetic flux travel less distance in air and keep the flux pattern the same as before then we can improve its efficiency. Motor structure didn&#39;t change too much in decades. If we can greatly improve its efficiency and along with battery capacity, lessen their weight, then an electrical car may be as practical as a gasoline car. The electrical airplane may also become practical. The power plant may generate more electricity with same energy consumed.

CROSS REFERENCE TO RELATED APPLICATION U.S. Patenet Documents

U.S. Pat. No. 4,146,210 March 1979 Koval et al. 254/375 U.S. Pat. No. 5,295,194 March 1994 Christensen, 381/190 Eugene J. U.S. Pat. No. 6,326,713 December 2001 Judson, John 310/112

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OF DEVELOPMENT

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REFERENCE OT SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX

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BACKGROUND OF INVENTION

Textbook definition of “magnetic saturation condition”: the maximum magnetic flux in a material, it can't be increased significantly even with a higher magnetomotive force applied.

Textbook definition of “soft magnetic material”: the soft magnetic materials show magnetic properties only when they are subject to a magnetizing force.

In order to increase the efficiency of an electrical motor, we need to maintain the same strength of the magnetic filed (close to but below the magnetic saturation condition) in the motor stator with less current flowing in the stator electrical winding than it originally was. In general, people use electrical wire with current flowing through it to generate magnetic field (as FIG. 1) and let magnetic flux flow through motor stator poles and motor rotor assembly (as FIG. 2) to create electromagnetic force to turn the rotor. But any soft magnetic material get its own magnetic saturation condition, so if we can maintain the same magnetic flux condition in stator as it was with less current flowing through the electrical winding, then we increase the efficiency of the electrical motor. And another thing we need take into consideration is that for any electric-magnetic device (motor, generator, speaker, transformer etc.), the magnetic flux pattern should not be changed after we do something to improve its efficiency so it will function just as before. Then a new stator structure (for motor generator) will be developed to achieve the result we want. Also this idea can be used in electrical generator, transformer and the rotor part (if it has electrical winding with it) of electrical motor (or generator). High power speaker can use the idea too.

The reluctance of a material is equal to (L/uA) L is the length of the material, A is its cross section area, u is the permeability. The permeability of ferromagnetic can be hundreds or thousands times bigger than the permeability of air. The reluctance may be hundreds or thousands times bigger in air than in ferromagnetic.

So if we can make magnetic flux pass less distance in the air, we can improve the efficiency of magnetic flux generation.

Now, for example of an induction motor (the most used motor—without electrical winding in the rotor assembly), magnetic flux generated by the electrical wire must pass through the small air gaps to reach the stator (as FIG. 4). In a bunch of wires of electrical winding, the small air gaps are between wires to wires and wires to the stator of electrical motor. This will cause energy loss in creating magnetic flux in stator and make electrical motor less efficiency.

If we can eliminate those numerous small air gaps between wires to wires and wires to stator, then we can use much less electricity to create same strength magnetic field. And at the all time, the magnetic flux pattern in the stator can't be changed so the motor (or generator) will function just as before. If we can make all these happen in a motor (or generator). The global electricity shortage will no longer be a problem.

The reason we can't create a super strong magnetic flux in stator is the magnetic saturation condition but we can use much less current to create same strength magnetic field as it was with the new design structure of stator.

BRIEF SUMMARY OF THE INVENTION

The way I develop to make motor more efficient is to design a different motor stator structure to keep the magnetic flux pattern the same as before and to let electrical wire get as close contact as possible to the part of the stator structure where we want the magnetic flux be generated. Because the magnetic flux pattern is the same as before so the motor will function just as before. The new shape of stator structure which gets extended volume to cover the space where electrical winding originally is. The extended stator part gets holes through to accommodate the electrical windings, so the position and formation of electrical windings will stay unchanged then the magnetic flux pattern in the stator will not be changed. The motor (or generator) will function as before but with its efficiency improved.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 the magnetic field created from electrical current

FIG. 2 the cross section view of a traditional induction motor

FIG. 3 the electrical wires position in the traditional motor & generator

FIG. 4 the small air gaps between wires to wires and wires to stator

FIG. 4-a the first step to build a mike 4001 stator

FIG. 4-b the second step to build a mike 4001 stator

FIG. 4-c the third step to build a mike 4001 stator

FIG. 4-1 the complete mike 4001 stator with its magnetic fields as the same as those in traditional stator

FIG. 4-2 mike 4002 stator with different winding layout compared to mike 4001 stator

FIG. 4-3 mike 4003 stator with different winding layout compared to mike 4001 stator

FIG. 5 traditional transformer

FIG. 5-1 mike 6001 design of transformer

FIG. 5-1-1 the cross section view of FIG. 5-1

FIG. 6 the traditional rotor with electrical winding

FIG. 6-1 the mike 6001 rotor with electrical winding (cross section view)

FIG. 7 the traditional speaker (cross section view)

FIG. 7-1 the mike 7001 speaker (cross section view)

DETAILED DESCRIPTION OF THE INVENTION

How to build the structure (mike 4001):

First: we can build a stator (like FIG. 4-a);

Second: we drill holes in the position where the electrical wires used to be (FIG. 4-b).

Third: we insert insulated painted electrical wire into those holes (FIG. 4-c).

The magnetic flux (FIG. 4-1) will flow like those in the traditional motor (FIG. 2) but both stator structures are not the same. The new design (mike 4001) consumes much less current due to much less air gap the magnetic fluxes need to overcome to reach the stator structure.

The new design of stator (mike 4001) will look like FIG. 411. With different electrical winding, it may look like FIG. 4-2 (mike 4002), FIG. 4-3 (mike 4003). The whole stator is in different shape from a traditional one and the material is soft magnetic material just as the traditional one. It is also a laminated structure to reduce eddy current. Electrical wires are insulated painted and inserted into holes, which are drilled through the stator in the place where those electrical wires originally are. (FIG. 4-1,4-2,4-3), and the size (diameter) of wire makes close contact with the stator wall in its hole. This design can also be used in electrical generator and transformer to increase their efficiency. This design also can be used in anywhere to use much less electrical current to generate same strength magnetic flux as it was (magnetic saturation condition is considered here).

The magnetic flux (FIG. 4-1) will flow like those in the traditional motor (FIG. 2) but both stator structures are not the same. The new design stator gets extended volume to cover the space where the electrical winding originally is. The new design (mike 4001) consumes much less current due to much less air gap the magnetic fluxes need to overcome to reach the stator structure.

Same procedure to build the mike 5001, mike 6001, mikes 7001 structures.

More Consideration of the Material of the Stator:

If a non-electricity conductivity soft magnetic material (it must be soft magnetic material too) can be found and used (physically strong enough) to build the new design structure (mike 4001,4002,4003,5001,6001,7001), the electrical winding wire can be build from hot liquid form poured into the hole then it will become the solid bare wire after it gets cold, this will create closest contact between wall of stator (or rotor, transformer core) holes and wires. They are welded together. Magnetic flux generation in structure will be even more efficient. In this way, we must prevent the hot liquid wire metal building up between the laminated stator pieces and cause unexpected result. Another way is we can squeeze a soft metal like bare copper wire into the hole of the stator built with the new material to get a close contact with the stator. There may already some more advanced ways to make a close contact like what we want but that is not the issue here. With the non-current conductivity character, we don't need insulated painted wire but just use bare wire to do the job.

This design is especially for motor (generator, transformer) using heavy wires [for ¼ hp (horse power) or bigger motor] not for very thin wires or it may be hard to build with the technology we have now. 

1. (for electrical motor & generator) What I claim as my invention is shown as FIG. 4-1 (mike 4001 design), a new shape of stator structure which gets extended volume to cover the space where electrical winding originally is. The extended stator part gets holes through to accommodate the electrical windings, so the position and formation (bunch of wires go together closely) of electrical windings will stay unchanged then the magnetic flux pattern in the stator will not be changed. The motor (or generator) will function as before but with its efficiency improved.
 2. (for electrical transformer) What I claim as my invention is shown as FIG. 5-1 & FIG. 5-1-1 (mike 5001 design), a new shape of core structure which gets extended volume to cover the space where electrical winding originally is. The extended core part gets holes through to accommodate the electrical windings, so the position and formation (bunch of wires go together closely) of electrical windings will stay unchanged then the magnetic flux pattern in the core will not be changed. The transformer will function as before but with its efficiency improved.
 3. (for rotor structure in electrical motor or generator) What I claim as my invention is shown as FIG. 6-1 (mike 6001 design), a new shape of rotor structure which gets extended volume to cover the space where electrical winding originally is. The extended rotor part gets holes through to accommodate the electrical windings, so the position and formation (bunch of wires go together closely) of electrical windings will stay unchanged then the magnetic flux pattern in the rotor will not be changed. The motor (or generator) will function as before but with its efficiency improved.
 4. (for high power speaker) What I claim as my invention is shown as FIG. 7-1 (mike 7001 design), a new shape of core structure in the speaker, which gets extended volume to cover the space where electrical winding originally is. The extended core part gets holes through to accommodate the electrical windings, so the position and formation (bunch of wires go together closely) of electrical windings will stay unchanged then the magnetic flux pattern in the core will not be changed. The speaker will function as before but with its efficiency improved. 